Downhole intervention and completion drone and methods of use

ABSTRACT

In one example, an apparatus includes a body, a propulsion system configured to move the body in a forward direction and in a reverse direction, and a reusable sealing and isolation element connected to the body and configured to be deployed so as to selectively seal and isolate sections or stages in a wellbore when the apparatus is disposed in the wellbore. The reusable sealing element may be selectively employed to isolate, and de-isolate, a portion of the wellbore, such as in connection with a perforation process for example.

BACKGROUND

After a conventional oil and gas well is drilled, cased, and cemented, more work is required and performed in order to bring the well into production. The next step after drilling is completing the well. The first step to completing the well is to hydraulically fracture, in multiple stages/zones, the lateral portion of the wellbore. Hydraulic fracturing, or simply ‘fracturing’ or ‘frac'ing,’ of the well may involve multiple companies, a large amount of equipment, and personnel on site to perform the fracturing.

For example, companies on site may include an oil company representative, a wireline company, a frac company, water haulers and services, a crane company, and downhole tool company. Each of these companies may have its own respective personnel on site as well. Equipment on site may include one or more cranes, one or more wireline vehicles, several high pressure pump vehicles, sand hoppers for hauling and dumping sand, one or more blending units for blending sand, chemicals, and any other additives needed, a central manifold/missile, one or more data vans, one or more chemical units, and water storage tanks.

Once all of the equipment to perform the frac are on site and rigged up to the well, they will begin the frac process. The process begins by installing a plug and perforation gun tool to the wireline. The plug and perforation tool is placed into the well using wireline and then pumped down the well with water forcing it to the desired location within the lateral portion of the wellbore. Once to the desired location, wireline then sets the plug, detaches from it and pulls up the wellbore to the next desired location. Once at the next desired location, wireline then sets off the perforation gun tool, normally jet charges, and perforates small holes into the side of the wellbore through the casing and cement into the formation. Once this is completed, wireline will then pull the tool out of the wellbore and the crane will help them set the tool down on the surface. Now that the plug has created a barrier and perforations have been made for water, sand, and chemical to enter, the frac company will then begin pumping frac fluids down the wellbore. Once the frac fluid mix build up enough pressure in the wellbore, against the plug, the frac fluid mix will then fracture the formation where the perforations were made. Once a positive fracture has been performed, the frac company will then slow to a stop on pumping. If necessary, some mixed fluids are then flowed back up the well and out of the wellbore. This is the completion of stage/zone one of the hydraulic frac. Wireline, once it has the perforation gun and plug reset and ready for the next stage/zone, will then repeat the process to complete stage/zone two of the hydraulic frac using the same process as previously described. They will pump down till they touch the previously set plug, and then pull back up the wellbore to the next desired location and set plug two and perforate stage/zone two, before pulling completely out of the wellbore. The hydraulic fracturing process of pumping mixed frac fluids for stage/zone two will then begin once wireline is out of the wellbore. The running of wireline, setting plugs and perforating, and fracturing the wellbore with mixed frac fluids is repeated 10 to 60, or more, times per every unconventional wellbore. Thus, creating multiple stages/zones per wellbore leaving multiple, 10 to 60 or more plugs left in the wellbore between and isolating each stage/zone. The plugs can vary in their composition, and may be made of polymers, ceramics, and metals. The wellbore cannot produce any product of oil, gas, water, etc. until the plugs are removed or remediated according to the design of the plug chosen to be used. Once the frac process of fracturing multiple zones, or to the oil companies desired needs for the well, the frac equipment and all other equipment on site is rigged down and moved off the well site. It is noted that some oil companies may perform a “zipper frac,” which refers to the idea that the frac company, and other necessary companies, will rig up to two wells on the multiple well site and work simultaneously on each well performing plug, perforate, and frac. One well frac process can take up to seven or more days to perform. Zipper fracs taking up to seven or more days to perform doing two wells.

Now that the frac has been completed successfully and all equipment and personnel has left the site, it is now time to remove/drill out, or remediate the existing plugs in the wellbore. This process is performed with either, or a few different types of equipment.

One of these operations is performed with coiled tubing, a downhole drilling motor, or bit, pumping unit(s), nitrogen unit(s) if needed, water tank(s), crane(s), and coiled tubing personnel. Other personnel will include the oil company's representative(s) and the downhole tool company's representative(s). This process is performed by continuous, one size and one piece, of tubing running in the wellbore with a motor, or bit, attached to the end of the tubing. The motor, or bit, is rotated for drilling by pumping fluids through the coiled tubing. Once the coiled tubing reaches the first plug, it will then begin pumping to rotate the motor, or bit, and drill out the plug. Coiled tubing will continue throughout the wellbore until it has reached its strength limit or has drilled out every plug left in the well bore. If coiled tubing has drilled out every existing plug, pumping commences to wash out any remaining debris potentially left in the wellbore. Once completed with the drill out process, coiled tubing will then pull out of the wellbore and rig down. This process can take between 24 and 40 hours to completely perform on 24 hour operations. The well is now ready to produce oil, gas, water, etc.

The other process is down with a Hydraulic Workover Rig and stick drill pipe, or tubing. Stick drill pipe, or tubing, is roughly thirty feet in length and each stick is connected with tongs and a collar for each stick, or joint of pipe. Equipment on location will include the rig and water tank(s). Personnel on location will include the Workover Rig personnel, oil company representative(s), and the downhole tool company's representative(s). This process is done by rigging the workover rig up to the well head, implementing its Blow Out Preventer on the well head, and then entering the wellbore. The wellbore is entered with the downhole motor, or bit, connected to the first joint of pipe. The workover rig will run in many joints of pipe, having to stop to pick up more pipe and connect the pipe, before completing the drill out of plugs process. Once the drill pipe has reached the first plug, water is then pumped down the wellbore to actuate the motor, or bit, and begin drilling out the plug until it is gone. This is down with either a downhole motor, which requires water to rotate the bit, or by a rotary drive, top or bottom drive, which physically rotates the pipe. Either process is performed until all the plugs have been drilled out. Once they have completed the drill out process, the workover rig will pull out of the wellbore, having to stop to disconnect every joint of pipe, and lay every joint of pipe down on the surface until they have come completely out of the wellbore. This process can take up to 72 hours to completely perform on 24 hour operations. They will then rig down and leave the well site, or move over to the next adjacent well.

Another process of completing the drill out of plugs process is done by a hydraulic snubbing unit, either stand alone or rig assisted. Stand Alone snubbing units can perform the drill out of plugs process on its own. The Rig Assisted snubbing unit completes this process with the assistance of the Hydraulic Workover Rig, as described in the previous description of existing processes. The Stand Alone snubbing unit process will have the snubbing unit, water tank(s), and a pump(s) on location.

Personnel will include the snubbing unit personnel, oil company representative(s), and the downhole tool company representative(s). The snubbing unit uses hydraulic jack cylinders to snub/force the pipe and motor, or bit, into the wellbore. The stroke lengths of theses cylinder is up to, or slightly more than, twelve feet. This process is limited due to the length of the stroke. Making this a lengthy process. The snubbing unit snubs the stick pipe, stops to pick up pipe and make connection, and runs the pipe into the wellbore until it reaches the first plug.

Once it reaches the first plug, the snubbing unit will either use a rotary table to physically rotate the pipe and drill out the plug, or pump water to actuate the motor, or bit, and rotate it to drill out the plug. Once the plug has been drilled out, the snubbing unit will continue to run into the wellbore until it drills out all of the existing plugs. Once the plugs are all drilled out, the snubbing unit will then begin snubbing the pipe out of the wellbore, disconnecting the joints of pipe, laying the pipe down on the surface, until it has completely come out of the wellbore. The snubbing unit will then rig down, move off site, or to the adjacent well. This process takes up to 96 hours or more to completely perform on 24 hour operations. The Rig Assisted snubbing unit performs the same operation as the standalone unit, only with the assistance of the work over rig.

The other process is done with a fiber optic cable unit, and an attached drilling device that is electrically powered. The equipment on site for this operation is the fiber optic cable unit, pump(s), and a water tank(s). The personnel on location are all cable unit personnel and oil company representative(s). This operation is performed by pumping the fiber optic cable down the wellbore with mixed fluids until it reaches the first plug. Once the first plug is reached the cable communicates electronically with the electric power drilling device and drills out the plug. This process of pumping and drilling out plugs is repeated until all plugs have been drilled out. Once all of the plugs are drilled out, the unit will pull out of the wellbore, rig down from the well, move off of site, or over to the next adjacent well. This process takes up to 24 to 36 hours to completely perform on 24 hour operations.

All of the described processes take up a minimum of 24 hours or more to perform. All these described processes typically do not take place until 15 to 40 days after the well is fractured. Thus, leaving the well in a nonproducing state for a significant amount of time.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which at least some of the advantages and features of the invention may be obtained, a more particular description of embodiments of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings.

FIG. 1 is an isometric view that discloses aspects of an example drone.

FIG. 2 discloses aspects of some example modules of a drone.

FIG. 3 discloses aspects of an example module A (RDM—(Retrieval and Deployment Module)).

FIG. 4 discloses aspects of an example module B (Wellbore Isolation Element).

FIG. 5 is a cross sectional view of an example module B (Wellbore Isolation Element).

FIG. 6 discloses an example module B (Wellbore Isolation Element), in a compressed state.

FIG. 7 discloses aspects of an example module C (Hydraulic Slips).

FIG. 8 discloses aspects of an example module C (Hydraulic Slips) in an extended state.

FIG. 9 is a cross sectional view of an example module C (Hydraulic Slips).

FIG. 10a discloses aspects of some example Radial Positioners

FIG. 10b discloses aspects of an example module D (Radial Positioners).

FIG. 11 is a cross sectional view of an example module E (Hydraulic Power Unit).

FIG. 12 discloses aspects of an example hydraulic manifold and valve assembly for distributing hydraulic fluid.

FIG. 13 discloses an example module F (Power Packs).

FIG. 14 discloses an example module G (Control)

FIG. 15 discloses aspects of an example of module H (Propulsion Units).

FIG. 16 is a cross sectional view of an example module H (Propulsion Units).

FIG. 17 is an isometric view of an example module H (Propulsion Units).

FIG. 18 discloses an example of a worm gear configuration in module H (Propulsion Units).

FIGS. 18a-18c disclose aspects of joint sections L that may be used to releasably join modules to each other.

FIG. 19 discloses aspects of an example module J (Module Sealed Connectors).

FIG. 20 discloses aspects of example module I (Module Collet Latch Connectors)

FIG. 21 discloses aspects of example power pack modules.

FIGS. 22-24 disclose aspects of an example power pack configuration (Module F).

FIGS. 25-31 disclose aspects of example methods for operation of an example drone.

FIG. 32 discloses aspects of an example computing entity 1M that may be employed with embodiments of the invention.

FIG. 33 is a section of an example perforation gun.

FIG. 34 is a perspective view of an example perforation gun.

DETAILED DESCRIPTION OF SOME EXAMPLE EMBODIMENTS

Embodiments of the present invention generally relate to apparatus, systems, hardware, software, computer-readable media, and methods for a downhole intervention and completion drone, and operation of the drone.

More particularly, some example embodiments of the invention may involve a downhole drone that may operate autonomously, and/or semi-autonomously, in carrying out any of the functions and operations disclosed herein in association with a drone, examples of which include, but are not limited to, downhole fracturing processes, functions, and operations. Fracturing processes include, but are not limited to, hydraulic fracturing, which may be referred to herein with the shorthand notation “frac'ing.”

An example drone, which may be referred to herein as a ‘Well Intervention Drone’ (WID), which may also be referred to herein simply as a ‘drone,’ may have various advantages over conventional single stage plugs or sliding sleeves. In conventional processes, a fracturing stage includes the setting of a fracturing plug to isolate each stage. These plugs remain in place throughout the fracturing process and must be removed prior to well production. A well intervention drone replaces the need to remove the fracturing plugs in a post-fracturing operation(s) disclosed herein. Conventional frac plugs and sliding sleeves require post-process remediation, such as in the form of drill-out, to be removed, and dissolvable plugs require specific downhole conditions and are prone to incomplete dissolution and large amounts of debris. These conventional processes are costly in terms of time and the requirement for use of expensive specialized equipment/services. The well intervention drone may be easily removed during the fracturing process, such as by wireline utilizing a fishing/retrieval tool or self-propulsion out of the well.

Example drones may perform a variety of functions including, but not limited to, to acting as, and/or implementing, a temporary, and reusable, fracturing plug in a wellbore. That is, in some embodiments, a portion of the drone may serve as a temporary, and reusable, fracturing plug, which may also be referred to herein as a ‘sealing and isolation element,’ which may, for example, be readily (re)moved, (re)located, and/or (re)deployed to a location, before and/or after a downhole process, such as a fracturing process for example, has been completed. An example drone within the scope of this disclosure may be operable to autonomously move itself uphole and downhole in a wellbore, to stop for a period of time at one or more locations within the wellbore, and/or to perform various other operations, examples of which are disclosed herein. The reusable sealing and isolation element may, when deployed, be able to withstand the pressure exerted by frac'ing fluid, and/or other materials, within the wellbore at locations above and/or below the reusable sealing and isolation element, such that little or no fluids or other materials are able to travel past the reusable sealing and isolation element.

Thus, embodiments of the reusable sealing and isolation element are not left in the wellbore after a fracturing process, and/or other process(es), have been completed. Rather, the reusable sealing and isolation element (i) may be removable, in its entirety, from the wellbore, and (ii) may not necessitate any remediation processes. Thus, embodiments of the invention may obviate the need for remediation and need not rely on passive processes such as post-placement disintegration of a fracturing plug. Instead, the wellbore may be completely clear of unwanted debris upon removal of the reusable sealing and isolation element.

Any aspect of the movement and/or positioning of the drone, such as direction, velocity, acceleration (positive or negative), start location, end location, intermediate locations, delay in drone movement, stopping drone movement, and non-movement of the drone, may be a function of the particular operation(s) to be performed, or being performed, by the drone.

Any function, process, or operation, performable by, and/or at the direction of, the drone, may be programmed as instructions that are carried by non-transitory computer-readable media and are executable by one or more hardware processors, and the hardware processors may comprise elements of the drone. Likewise, where the drone is operated in other than an autonomous mode, any aspects of the operation of the drone may be programmed as instructions that are carried by non-transitory computer-readable media and are executable by one or more hardware processors, and the hardware processors may comprise elements of the drone and/or elements of an apparatus remote from the drone.

While reference is made herein to example processes such as fracturing, the scope of the invention is not limited to any particular mining or downhole process, nor is limited for use with any particular material, or materials, targeted for extraction in connection with processes such as, but not limited to, fracturing processes. Aspects of example embodiments may be employed in other than downhole fracturing processes, and embodiments may find application in other than underground mining processes.

Embodiments of the invention, such as the examples disclosed herein, may be beneficial in a variety of respects. For example, and as will be apparent from the present disclosure, one or more embodiments of the invention may provide one or more advantageous and unexpected effects, in any combination, some examples of which are set forth below. It should be noted that such effects are neither intended, nor should be construed, to limit the scope of the claimed invention in any way. It should further be noted that nothing herein should be construed as constituting an essential or indispensable element of any invention or embodiment. Rather, various aspects of the disclosed embodiments may be combined in a variety of ways so as to define yet further embodiments. Such further embodiments are considered as being within the scope of this disclosure. As well, none of the embodiments embraced within the scope of this disclosure should be construed as resolving, or being limited to the resolution of, any particular problem(s). Nor should any such embodiments be construed to implement, or be limited to implementation of, any particular technical effect(s) or solution(s). Finally, it is not required that any embodiment implement any of the advantageous and unexpected effects disclosed herein.

In particular, one advantageous aspect of at least some embodiments of the invention is that the use of fracturing plugs which require post-process remediation may be eliminated. Advantageously, post-remediation processes typically required with conventional fracturing plugs may be reduced, or eliminated. Advantageously, some embodiments may provide for a reusable sealing and isolation element that can be selectively located, and used/reused, at one or more locations in a wellbore. As another example of an advantageous aspect, embodiments may provide for a reusable sealing and isolation element which may be implemented as an element of, or separately from, a drone. Embodiments of the invention may provide for autonomous deployment and redeployment of a sealing and isolation element, such as a reusable sealing and isolation element.

A. Example Materials and Environments for Some Embodiments

In general, embodiments of the invention, including a drone, may employ a variety of different materials for their various components. Such materials may be particularly well suited for use in underground mining and fracking operations where the materials may be exposed, for example, to any combination of high and low temperature extremes, corrosive materials, fluids, gases, fluid/gas/solids mixtures, high and low pressures, high noise levels, vibrations, concussions, explosions, shock waves, dust and other particulates, abrasive materials, flammable materials, and potentially explosive materials such as dust and gases. Examples of materials, which may be used in any combination, that may be employed in connection with a drone and its various components may include, but are not limited to, titanium, a family of austenitic nickel-chromium-based superalloys sold under the registered mark INCONEL®, steel, copper, brass, aluminum, nickel, tungsten, ceramics, plastics, rubber, and composite materials which may include components such as, for example, carbon and carbon fibers. Any component(s) of the drone may employ materials that are non-sparking, chemically inert, and/or have other properties compatible with conditions that could be encountered while the drone is deployed. Finally, any suitable manufacturing process(es) may be used to produce components of the drone and such processes include, but are not limited to, welding, brazing, milling, turning, boring, casting, molding, three dimensional (3D) printing/additive manufacturing, shaping, and cutting.

B. Aspects of Some Example Embodiments

As disclosed herein, embodiments of a drone may comprise a variety of different combinations of different functional modules which may be releasably be connected to each other. In general, the drone may be configured to suit whatever processes are to be performed by the drone. Due to its modular construction, embodiments of the drone can be readily configured and re-configured in the field as needed. In addition to its physical reconfiguration, the drone may also be configured to enable programming changes, such as relating to functions to be performed by the drone, to be made on the surface at the time of configuration and/or when the drone is in situ in the wellbore. Programming changes, whether implemented when the drone is on the surface or in situ, may be implemented by a hardwire (such as wireline), optical (such as fiber optic), and/or wireless connection between a user interface (UI) and the drone. The physical and programmatic flexibility of the drone may enable it to be quickly and easily adapted to whatever configuration/function may be required. It is noted that while example embodiments disclosed herein may refer to a particular order of modules in the drone, the scope of the invention is not limited to any particular order, or combination, of modules in a drone.

As well, in order to simplify field assembly, a device data communications method may be employed that counts the number of sections from the Controller section and use that to address the devices in each section. The sections will identify themselves to the controller when the controller comes online. In this way, the technician may be able to simply plug and fasten the sections together in the desired order and the sections will report into the controller which, in turn, will report to the User Interface (UI) the individual serial numbers and software revisions for each module or section. The user may set the mission parameters—number of stages, stage locations and distances, end of stage conditions—as needed. Thus, embodiments of the drone may operate based on data communications distributed control or by way of individually hardwiring the control devices.

With general reference to aspects of the operation of embodiments of the drone, sensors, and other devices, within the drone may collect, but not limited to, temperature and pressure data pre-frac, during the frac, and post-frac. Pre-frac, the drone may collect pressure and temperature differential data from each side of the sealing and isolation element. In other words, as the drone is set, and the seal is isolating an already frac'd stage from a stage that is about to be frac'd, there is a differential in pressure and temperature. The drone captures that data and stores it. So, the pre-frac is before the stage is perforated and frac'd. Temperature and pressure will change during perforation and during the frac. When the sealing and isolation element is not engaged, the drone also captures and stores the temperature and pressure data. That data may be collected uphole and downhole of the WIE (Wellbore Isolation Element) while the sealing and isolation element is engaged or disengaged. During the frac, the WIE will engage the sealing and isolation element, sealing and isolating the wellbore, and the drone may collect data uphole and downhole of the sealing and isolation element. After the stage is frac'd in the wellbore, post-frac, the drone may collect data uphole and downhole of the sealing and isolation element while the WIE is engaged. Data may be collected as the drone propels from stage to stage in the wellbore, or from stage to next predetermined or preprogrammed location. All data collected by the drone may be stored within the drone, or transmitted to other tools, and devices, downhole or to equipment and other devices on the surface.

With reference first to FIG. 1, details are provided concerning an example embodiment of a Well Intervention Drone (WID). The example drone is generally denoted at 100, and may comprise a body or frame that supports and/or comprises various components and modules. The drone 100 may operate autonomously, semi-autonomously, and/or may be remotely controlled. In some embodiments, the drone 100 may be operable in any of the aforementioned modes. The example drone 100 may operate in connection with various other equipment and systems which may be located downhole in a wellbore and/or at or above the surface of the earth.

As used herein, autonomous operation embraces drone-based operation and control of the drone independent of any control signals from other entities, although even when operating autonomously, the drone may nonetheless communicate with one or more other entities. Semi-autonomous operation embraces an operational mode in which some operations of the drone are controlled by the drone independent of control signals from other entities, and other operations of the drone are performed based on control signals received from other entities. Remote control embraces an operational mode in which all operations of the drone are controlled remotely, such as through the use of a control interface at a surface location, for example. The control interface may be operated by a human operator and connected to the drone in such a way that the human operator can send control signals to, and receive feedback signals from, the drone.

As shown in FIG. 2, the drone 100 may comprise various modules, each with associated functionality. These modules may include a Retrieval and Deployment Module (RDM) (Module A), Wellbore Isolation Element (WIE) (Module B), hydraulic slips (Module C), Radial Positioners (Module D), hydraulic power unit (HPU) (Module E), power pack (Module F) and controls (Module G) as well as one or more propulsion units (Module H) for vertical and lateral movement in the wellbore, and one or more module connectors (Module I and J). Any of the aforementioned components of the example drone 100 may be modular in form so that they may be serviced/replaced independent of each other for fast onsite maintenance and assessment. The modular components may also allow for ready configuration/reconfiguration, in the field for example, of drone 100 elements based on job-specific requirements and/or conditions within and/or outside of a wellbore. As such, the modules may include quick-connect/disconnect connections for mechanical elements, and for electrical/electronic elements.

Referring next to FIG. 3, the RDM (Module A) is on the up-hole end of the drone 100. This RDM (Module A) may be used to create a hard physical connection between the drone 100 and other tools (not shown) tethered to the surface. Examples of these connections will include but are not limited to connection to the perforating gun when originally placing the drone and with wireline when retrieving the drone. In addition to tethering to the surface, the RDM is outfitted with a load sensor(s) 1A, strain sensor(s) 2A, pressure sensor(s) 3A, temperature sensor(s) 4A, resonant inductive link 5A for receiving and transmitting data and wireless charging of batteries when the drone 100 is positioned in the wellbore, or elsewhere, and a connector for connecting the aforementioned elements to the rest of the drone 100. The pressure sensor(s) 3A may measure and record the pressure in the wellbore at any location including but not limited to in front of the WIE before, during and after the frac'ing process. The pressure sensor(s) 3A may also detect a rapid and brief pressure change such as rapid pressure changes during the frac'ing process and/or a pressure pulse initiated at the surface that can be used to communicate, control and/or command the drone 100 to perform specific actions. The temperature sensors (4A) may measure and record temperatures in the wellbore at any location including but not limited to in front of the WIE before, during and after the frac'ing process. This pressure and temperature information is then sent to the control unit for storage and subsequent transmission for evaluation. The load sensor(s) 1A may determine that the drone 100 is in contact with a perforating gun or other tools and devices (not shown) between stages for verification of correct operation. Finally, the strain sensor(s) 2A may be used with a fishing retrieval system or other tools and devices (not shown) to alert the drone 100 to retract the hydraulic slips (Module C), propulsion units (Module H), and WIE (Module B) using an emergency reserve power supply (not shown) prior to retrieval, such as in a rescue situation or, but not limited to, in completion of the frac'ing process, completion of the well and or required operation.

Downhole from the RDM (Module A) is the WIE (Module B) as shown in FIG. 4 and FIG. 5. The multi-use WIE (Module B) may include a sealing and isolation element 1B, seal piston 2B, seal compression rod 3B, sealing element clamp 4B, as well as various rubber seals. Depending upon the embodiment, the sealing and isolation element 1B may be constructed with a variety of different materials suitable for use in the example operating environments disclosed herein. Such materials may include, but are not limited to, operationally suitable polymers such as silicone, HNBRs, EPDM, FKM, and chlorosulfonated polyethylene (CSPE) synthetic rubbers (CSM) sold under the mark Hypalon®, and embodiments of the sealing and isolation element 1B may be embedded with studs and/or other gripping elements, which may be made of metal, ceramic, and/or, other suitable materials.

It is noted that while example embodiments of a WIE (Module B) and a temporary reusable sealing and isolation element are disclosed herein, those disclosures are provided by way of illustration and are not intended to limit the scope of the invention in any way. More generally, any other systems, devices, and mechanisms that may be deployed by, and/or as part of, a drone and that are operable to temporarily plug, seal, and/or isolate, sections within a wellbore without requiring any post-remediation work, may be employed and are considered to be within the scope of this disclosure. Moreover, the example WIE (Module B) disclosed herein, as well as the temporary reusable sealing and isolation element, are examples of a structural implementation of a means for temporarily sealing and isolating sections within a wellbore. One or more of such means may be implemented without requiring post-remediation of a sealing and isolation element.

In operation, the multi-use WIE (Module B) may be axially compressed so that it expands radially to seal off and isolate the wellbore stages as shown by item 5B in FIG. 6. This operation of the multi-use WIE (Module B) may be implemented during a process such as hydraulic fracturing so that the fracturing fluid, which may comprise a mixture of water, chemicals, and sand for example, cannot flow past the WIE (Module B) of the drone 100. That is, the multi-use WIE (Module B) may be operated so as to temporarily seal and isolate a portion of the wellbore. The multi-use WIE (Module B) may be located on the seal compression rod 3B, reaching from the seal piston 2B, and connected to the RDM (Module A). A control signal from the control unit may activate the HPU (Module E) to actuate the seal piston 2B, moving the seal compression rod 3B, pulling the RDM (Module A) towards the seal piston 2B thereby compressing the multi-use WIE (Module B) between the seal piston 2B and the RDM (Module A) until the sealing and isolation element 1B contacts the well casing with sufficient force to maintain a seal during, but not limited to, hydraulic fracturing. In addition to providing compression and seating for the sealing and isolation element, the seal compression rod 3B may have a center bore through its length allowing for installation of wiring for sensors on the RDM (Module A) to pass through to the control unit. Along with providing sealing, the contact between the multi-use WIE (Module B) and the wellbore casing comprises a portion of the forces. That is, when the WIE engages the sealing and isolation element and the sealing and isolation element compresses and conforms into the ID of the casing, the WIE shares and takes some of the load when the frac is taking place. When the frac is taking place, the pressure increases the load on the front uphole section of the drone. So, the WIE shares some of that load when it is engaged, and that load may help to lock the drone 100 in position.

The hydraulic slip module (Module C) may be operable to lock the drone 100 in position, as shown in FIG. 7, FIG. 8 and FIG. 9. The hydraulic slip module (Module C) may comprise hydraulic slip piston(s)/die(s) 1C, hydraulic slip cylinder housings 2C, hydraulic slip cylinder caps 3C, along with various seals (not shown) including, but not limited to, hydraulic slip cylinder seal(s), and hydraulic slip piston/die seal(s). The hydraulic slip piston/die seal(s) may be disposed about the hydraulic slip piston/die(s) 1C and may serve to prevent leakage of hydraulic fluid and prevent contaminates from entering the assembly. The hydraulic slip module (Module C) may be connected to the hydraulic power unit (HPU) (Module E) by way of one or more hydraulic line connections 4C that may supply the hydraulic slip cylinder housings (2C) with hydraulic fluid to actuate the slip piston/die(s) 1C.

The number of hydraulic slip piston/die(s) 1C may be customized/configured and optimized based on job-specific requirements. The hydraulic slip piston(s)/die(s) 1C may be elliptical in shape to maintain the hydraulic slip piston orientation relative to the direction of force applied during hydraulic fracturing to maintain position of the drone 100 at a desired location within the wellbore. These hydraulic slip piston(s)/die(s) 1C may serve to limit the shear force on the multi-use WIE (Module B) to maximize the number of sealing cycles achievable by the multi-use WIE (Module B). The head of the hydraulic slip piston(s)/die(s) 1C may be tapered and knurled to maximize holding force when axial pressure is applied to the drone 100. The hydraulic slip piston(s) may be removable during servicing to enable replacement of the hydraulic slip piston(s)/die(s) 1C as well as replacement of the corresponding seal(s) as needed. As well, the hydraulic slip piston(s)/die(s) 1C may help to secure the drone 100 in a desired position in the wellbore, such as by extending into contact with the casing. As illustrated in FIG. 8 the slip piston(s)/die(s) are in their extended state.

In FIG. 10a , Radial Positioners comprising one or more positioning wheels 1D-1 and wheel lever arms 2D-1 may serve to radially position the drone 100 in the wellbore (not shown). The positioning wheels 1D-1 may be equally spaced around the radius of the drone 100, although such spacing is not necessarily required. Each of the positioning wheels 1D-1 may be extended, and retracted, by a corresponding wheel lever arm 2D-1. These operations may be implemented, for example, by way of a centered linear actuator (not shown) which may press the positioning wheels 1D-1 radially outward into contact with the casing with a predetermined force, and the linear actuator may also impart some axial motion to the positioning wheels 1D-1 so that the positioning wheels 1D-1 are moved both radially and axially by the corresponding wheel lever arm 2D-1. The linear actuator may activate through electrical and/or mechanical mechanisms, such as a hydraulic system for example. As such, the Radial Positioners may serve to center the drone 100 within the wellbore, such that a longitudinal axis of the drone 100 is generally collinear with a central axis defined by the casing in the wellbore, and may also help to reduce friction/drag between the drone 100 and the casing in the wellbore. As well, the positioning wheels 1D-1 may comprise one or more encoders or resolvers, similar to an odometer for example, that may be used to determine the distance that the drone 100 has traveled in the wellbore.

As illustrated in FIG. 10b , Radial Positioners may be comprised of one or more free idling wheels (1D). These idling wheels may be comprised of one or more bearings mounted in the center hub of each wheel with a rotary shaft (2D) installed through the center. The rotary shaft (2D) may act as an axel and may be mounted to the wheel axel frames (3D). These wheel axel frames (3D) may be installed onto the cylindrical body/housing (4D) through a variety manufacturing and fabrication processes. The cylindrical body/housing (4D) may have a through way (5D) for routing through the module. As such, the Radial Positioners may serve to center the drone 100 within the wellbore, such that a longitudinal axis of the drone 100 is generally collinear with a central axis defined by the casing in the wellbore, and may also help to reduce friction/drag between the drone 100 and the casing in the wellbore. As well, the positioning wheels 1D may comprise one or more encoders or resolvers, similar to an odometer for example, that may be used to determine the distance that the drone 100 has traveled in the wellbore.

The HPU (Module E) may be operable to distribute hydraulic fluid to the hydraulic slip piston(s)/die(s) 1C, the positioning wheels 1D, propulsion unit linear actuator(s) 8H, and the multi-use WIE (Module B), as shown in FIG. 11. The HPU (Module E) may include the following components: the hydraulic manifold and valve assembly 1E, the hydraulic micropump 2E, the pump motor 3E, and the hydraulic fluid reservoir 4E, pass through route 5E, and a pressure rated electrical connector 6E. FIG. 12 illustrates an example manifold and valve assembly. The valves in the manifold and valve assembly may be electric over hydraulic solenoid controlled directional control valves. The valves, or solenoids, control the direction of hydraulic flow through the manifold by opening and closing pathways, or changing the direction of flow. The solenoids are operated by an electric coil that is coiled around its center core. The manifold may be a machined, or 3D printed, block of flow paths that act as the hydraulic circuit board and houses the solenoids/valves. This assembly is what manages the distribution of hydraulic fluid throughout drone 100. This assembly may be comprised of a hydraulic fluid inlet(s) (7E), pressure rated valve(s) (8E), hydraulic outlet port(s) (9E), and hydraulic return port(s) (10E). The HPU (Module E) may also comprise various other components including, but not limited to, a filter, multiple valves, pressure gauges, a shutoff valve, a pressure release valve, and a power source such as an electric motor to power the hydraulic micropump 2E.

In operation, a microcontroller 3G (see FIG. 14) may control the operation of the HPU (Module E). For example, the microcontroller may start an electric motor which, in turn, may drive the hydraulic micropump 2E which cycles hydraulic fluid from the hydraulic fluid reservoir 4E through a filter to a pump inlet of the hydraulic micropump 2E. The fluid is then pumped out of the hydraulic micropump 2E through an outlet and manifold and valve assembly. As well, the microcontroller may also open the desired valve of the manifold and valve assembly 1E to allow hydraulic fluid to pass through to the desired hydraulic line. If at any point during HPU (Module E) operation, a predetermined hydraulic fluid pressure limit is reached, a pressure relief valve may open, thereby relieving the excess pressure, and providing and maintaining safe operating conditions for the system.

In general, the microcontrollers disclosed herein, which may take the form of processors, may be connected to semiconductor switches, by way of which the microcontrollers may control the operation of any of the disclosed components. Such components include for example, pumps, valves, motors, sensors and other devices, which may be electrical devices.

With reference now to FIG. 13, the power pack (Module F) may comprise a series of high temperature rated batteries 3F that can be either single duty or rechargeable. The batteries may be assembled into multiple packs which can then be interconnected and encased inside a chassis (2F and 4F) for support and cable management. These battery packs may be separated by spacers (5F) that compartmentalize each battery pack. The chassis may then be mounted inside a sealed housing (1F) or module. Multiple housings or modules may be interconnected to increase operational life of the drone 100 in the wellbore as needed. The high temperature, that is about 100 C or higher, rated batteries 3F power the drone 100, providing power to the motors (for example 3E and 1H), sensors (for example, the load sensor(s) 1A, strain sensor(s) 2A, pressure sensor(s) 3A, and temperature sensor(s) 4A), and the microcontrollers 3G. Due to the relative length of power packs (Module F), there may be articulation points provided in the series that connects each power pack to allow for flexibility that may better enable the drone 100 to navigate bends and turns within the wellbore.

With reference to FIG. 14, the control module (Module G) consisting of one or more microcontrollers 3G. The microcontroller 3G may perform various functions, including controlling the operation of the drone 100. In more detail, the microcontroller 3G may be operable to perform functions including, but not limited to, data logging, processing, and executing commands based on sensor information, controlling the hydraulics (for example, the hydraulic micromotor 3E and manifold 1E), as well as controlling the propulsion of the drone 100.

Data transmission between the drone 100 and equipment on the surface may be poor, or non-existent in some circumstances while the drone 100 is downhole in the wellbore. Thus, there are forms of data transmission including, but not limited to, downhole data transmission between the drone 100 and another tool, or other device(s), that may be tethered or connected to equipment at the surface that may be but not limited to wireline, e-line, fiber-optic or other equipment. This data transmission may occur between the drone 100 and these other devices by means of close proximity resonance. Or, upon removal of the drone 100 from the wellbore, the control module (Module G) may be accessed to recover data, wellbore activity and diagnostic logs, but not limited to, with the purpose of more accurately understanding the details of conditions and the tasks performed downhole. This data transmission may occur through either physical hardline connection, Bluetooth or WiFi. The data may then be uploaded to a host either locally or cloud based for further processing and analysis.

The Propulsion Units (Module H) may be utilized to propel the drone 100, forward or backwards, in the wellbore and one example of the Propulsion Units (Module H) is disclosed in FIG. 15, FIG. 16, FIG. 17, and FIG. 18. The motor 1H may be positioned between an upper casing 2H and a lower casing 3H. The motor 1H may be connected to a gear box 4H that may include gears 5H or as illustrated in FIG. 18 with a worm drive 11H and worm gear 10H which transfer power from the motor 1H to the drive wheels 6H. The motor casing 2H/3H may extend out from the drone 100 body so that the wheels 6H contact the inner surface of the casing in the wellbore. The extension of the motor casing 2H/3H may be performed, for example, by way of a link 7H and a linear actuator 8H. Particularly, extension and retraction of the linear actuator 8H may cause a corresponding movement of the link 7H, to which the linear actuator 8H and motor casing 2H/3H are connected, so that the motor casing 2H/3H is extended/retracted.

The example Propulsion Units (Module H) may comprise a through route 9H, such as a passageway, for elements such as cables (which may be but not limited to wires, hydraulic lines, or optical fibers) for communication, control, and/or other functions, to pass through the Propulsion Units (Module H). Operationally, the drone 100 may be pumped down the well, with fluid for example, with the Propulsion Units (Module H) retracted so that the Propulsion Units (Module H) do not contact the inner surface of the wellbore casing. Alternatively, the drone 100 may propel itself through the wellbore to a pre-determined location or depth in the wellbore. Prior to self propulsion through the wellbore, the linear actuator 8H may extend the motor casing 2H/3H outside of the drone 100 body so that the motor casing 2H/3H, particularly the drive wheels 6H, is in contact with the inner surface of the casing of the wellbore. This actuation may be completed through electrical or hydraulic means. Once extension of the motor casing 2H/3H has been completed, the drone 100 may be able to propel itself back and forth along the inside of the casing in the wellbore. After the drone 100 reaches a desired position in the casing in the wellbore, the motor casing 2H/3H may be retracted.

While the example Propulsion Units (Module H) may comprise a propulsion system that uses a power source connected to one or more drive wheels, the scope of the invention is not limited to this particular implementation of a propulsion system. Alternative propulsion systems may comprise, for example, water jet propulsion, compressed gas propulsion, one or more walking feet, or a caterpillar or inch-worming drive system. Where walking feet are employed, the propulsion system may involve the use of hydraulic or electrical inch worming by use of a linear actuator throughout the lateral section of the well. The drone may include a water jet, such as a pump for example, that can use fluid already in the wellbore for propulsion by sucking in the fluid and then expelling the fluid from the water jet to propel the drone.

With reference next to FIGS. 18a-18c , details are provided concerning further aspects of some example radial positioners. In some embodiments, a joining section L1, which may be employed in pairs, may have a two bolt configuration so that the pair of joining sections L1 collectively form an articulating joint whose portions, or joining sections L1, each are able to turn about 90 degrees relative to the other joining section L1. This example configuration may result in the positioning of two idler wheels L2 at each joint, which are able to center each section. One or both of the idler wheels L2 may be configured with a rotary optical encoder, or other device of comparable functionality, to determine the WID position in the well casing.

As shown in FIGS. 18a-18c , the joint sections L1 may enable the idler wheels L2 to be mounted in two positions, such as at the up hole end of the drone or the down hole end of the drone. The idler wheel L2 may be spring loaded L3, or otherwise biased, to keep the drone centered in the casing. The center of the joint formed by the joint sections L1 may configured with a passageway to accommodate a cable connector for the power, instruments and data communications. When assembling the drone on site, the joint sections L1 may be joined by the two bolts, or other fasteners, and the electrical connection, simplifying assembly and disassembly of the drone.

With reference next to FIG. 19 and FIG. 20, one or more Module Connectors (Module I and J) may be provided that may be used to connect the drone 100 to other equipment, and/or may be used to interconnect various sections and modules of the drone 100. FIG. 19 illustrates an example of module sealed connectors (module J). These connectors may include a male body (1J), a threaded coupler (2J), and a female body (3J). The module sealed connectors allow for sealing between the male body (1J) and the female body (3J). The threaded coupler (2J) may come in two halves and be fastened together to sit on the male body (1J). FIG. 20 illustrates an example of module collet latch connectors (Module I). These connectors may include a female collet body (1I), collet locking sleeve (2I), and a male collet body (3I). The module collet latch connectors are assembled with the collet locking sleeve (2I) on the male collet body (3I). The male collet body (3I) is inserted in the female collet body (1I) until it locks into position. Once the collet bodies are locked into position, the collet locking sleeve (2I) may be moved forward and rotated to ensure secure coupling. Once rotated into position the collet locking sleeve may be held in position with set screws. The module collet latch connectors may allow for some flexibility allowing drone 100 to have minor bending between modules. In some embodiments, one or more of the Module Connectors (Module I and J) may take the form of quick connect/disconnection connectors. No particular type of connection or coupling is required however.

Turning next to FIGS. 21-24, some example power pack modules (Module F) and configurations are disclosed that may be employed in a drone, such as the example drone 100. As noted elsewhere herein, various components of a drone may be powered by one or more power packs (Module F), although other types of energy sources may alternatively be employed.

The battery, or batteries, contained in the power pack (Module F) employed in a drone need not be of any particular type. Batteries used in embodiments of the invention may be rechargeable. Example rechargeable batteries that may be used in some embodiments include, but are not limited to, nickel-cadmium (Ni—Cd), nickel metal hydride (Ni-MH), lithium-ion (Li-Ion), and lithium polymer (Li-Po). Examples of non-rechargeable batteries that may be employed in some embodiments include, but are not limited to, alkaline batteries, lithium batteries, carbon-zinc batteries, and batteries with manganese-based cathode materials. In at least some embodiments, the batteries employed in a drone do not generate gases or other materials that may potentially be explosive, toxic, or hazardous. In some embodiments, the batteries may be recharged wirelessly and remotely, even while the drone is located downhole. In one example embodiment, a drone docking station may be provided that includes a transformed configured to use close proximity resonant charging, and/or any other type of wireless charging, to recharge the batteries. One or more drone docking stations may be provided downhole and/or on the surface.

As with the other modules disclosed herein, a power pack (Module F) may be located at any suitable position in the length of the drone. In some example embodiments, the power pack (Module F) and control (Module G) may be located on the uphole end of the string, that is, the string of modules that make up the drone. Other arrangements may be employed however, and this arrangement of the power pack (Module F) is presented by way of example and is not intended to limit the scope of the invention in any way.

FIG. 21, in particular, discloses a block diagram of an example power pack (Module F). As shown, a power pack (Module F) controller may be provided that is configured to transmit and receive various types of signals, including control signals and reporting signals. For example, the power pack (Module F) controller may receive, and pass along, signals from sensors, such as temperature sensors, voltage sensors, and output current sensors, indicating various operating parameters of one or more batteries. In the example of FIG. 21, one or more batteries may be connected, in series for example, to a battery bus. Other embodiments may employ a parallel arrangement of batteries. Various other aspects of the example of FIG. 21 are referred to in the following ‘Design Notes’:

1—Power Pack Modules are connected end to end (in parallel) with bolted connectors to meet load and capacity needs for each well.

2—Communication addresses are arbitrated using an additive pulse scheme on the CommAddrIn/Out lines.

3—Cells are temperature monitored in groups of three.

4—Controller should disconnect the bank from the bus if there is an over temperature or over current condition.

5—Power Pack is voltage and current monitored.

6—Bus is voltage and current monitored.

7—Controller tracks cell bank usage.

8—Controller is powered (diode protected) from both Battery Bus and Module Bank.

9—Communication TBD (12C or similar).

FIGS. 22 and 23 disclose aspects of example power packs (Module F) and mechanisms for connecting one power pack (Module F) to another power pack (Module F). As shown, each of the power pack (Module F) may be located within a respective sealed power packs (Module F) casing. In general, the power packs (Module F) may be connected in such a way as to enable electrical communication between the power packs (Module F), while also preventing or minimizing the ingress of any foreign material(s) that could compromise, or defeat, the operation of the power packs (Module F), and while providing a power packs (Module F) connection suited to withstand the rigors of mining operations and environments. Further details concerning aspects of one particular example mechanism for connecting power packs (Module F) are disclosed in FIGS. 22 and 23.

As shown in FIGS. 22-24, multiple power packs (Module F) may be connected together. In some embodiments, and end-to-end connection arrangement may be employed in which two or more power packs (Module F) are connected end-to-end. This arrangement is provided by way of example however, and the scope of the invention is not limited to this type of arrangement. In one alternative arrangement, power packs (Module F) may be connected together and arranged side-by-side in a cluster arrangement.

C. Example Methods

Attention is directed now to FIGS. 25-31, which disclose various example methods concerning the operation of a drone, such as the drone 100 for example. As to such methods, and any of the other disclosed processes, operations, methods, and/or any portion of any of these, it is noted that such may be performed in response to, as a result of, and/or, based upon, the performance of any preceding process(es), methods, and/or, operations. Correspondingly, performance of one or more processes, for example, may be a predicate or trigger to subsequent performance of one or more additional processes, operations, and/or methods. Thus, for example, the various processes that may make up a method may be linked together or otherwise associated with each other by way of relations such as the examples just noted. In some embodiments, the order of the disclosed processes of a method may be changed, and/or one or more processes of one or more of the methods may be omitted. Thus, the methods disclosed in FIGS. 25-31 are provided only by way of example, and are not intended to limit the scope of the invention in any way.

Turning first to FIG. 25, an example method is disclosed that concerns various processes that may be performed subsequent to a drone entering a stand-by mode. The processes referred to in FIG. 25 are set forth in further detail in FIGS. 26-31.

With particular reference to FIG. 25, an example stand-by mode of a drone is disclosed. In general, the stand-by mode may be entered, automatically in some embodiments, upon satisfaction of one or more specified conditions, and the stand-by mode may likewise be exited, and a different mode entered by the drone, or the drone shut down, automatically in some embodiments, upon satisfaction of one or more specified conditions. While in the stand-by mode, the drone, or a remote operator, may modify one or more configuration parameters of the drone. For example, if the drone is in a stand-by mode, the drone may enter a low power state in which all non-essential systems of the drone may be shut down to conserve battery power. Modification of such configuration parameters may be performed automatically when the drone enters the stand-by mode.

With continued attention to FIG. 25, and turning to FIG. 26 as well, it was noted elsewhere herein that the drone may implement and/or comprise a temporary, reusable, sealing and isolation element in a wellbore. After the associated processes are completed, it may be desired to move the drone to another location in the wellbore to implement a temporary, reusable, sealing and isolation element in that location. One example of a method, denoted generally at ‘Move to Next Stage’ for relocating the drone is referred to in FIG. 25, and detailed in FIG. 26. As shown in FIG. 26, once the drone is configured such that it has been deployed as a temporary, reusable, sealing and isolation element, the drone may then go into the stand-by mode. During this time that the drone is in stand-by mode, fracturing processes and/or other processes may be performed uphole of the WIE (Module B) of the drone.

As shown in FIG. 27, an initial placement method is disclosed in which a drone is deployed as a temporary, reusable, sealing and isolation element. Once the drone is so positioned and configured, the drone may enter the stand-by mode.

In FIG. 28, a method is disclosed for configuring and handling of a drone after a last stage of a process, such as a fracturing process, has been completed. Once the drone is so positioned and configured, the drone may enter the stand-by mode.

With regard now to FIG. 29, an ultimate time out method is disclosed in which, after a drone has been deployed as a temporary, reusable, sealing and isolation element in the wellbore, the drone is re-configured for movement in the wellbore to another location. Upon completion of the reconfiguration, the drone may enter the stand-by mode.

In FIG. 30, aspects of some example methods are disclosed for communicating with, and/or controlling, a drone. Any one or more of the following ‘Notes’ may apply to some embodiments, but may not apply to other embodiments, and are not intended to be limiting of the scope of the invention in any way.

Notes on Comms:

1—Down hole communications are very limited without wire or fiber. 2—Acoustic range is limited to a few hundred feet. 3—Radio frequencies are very limited also. 4—The lower the frequency the longer the range. 5—Lower frequencies result in lower data rates. 6—Since wire or fiber occupy the same casing space as working tools you can only have the wire or the working tool, not both. 7—This communication scheme is based on a short range (less than 250 ft) and DTMF acoustic data transmission. (like Touch Tone phones) 8—Data rates would be 100 baud or less. 9—This is optional and is not required for the WID basic operation.

FIG. 31 discloses an example method for configuration and operation of a drone in the event that a screen, or screen-out, condition is detected. This condition may be detected by sensors of the drone and/or by other sensors that are able to communicate directly or indirectly with the drone. As used herein, a screen-out condition refers to a condition in which further injection of fluid, such as a fracturing mixture, would exceed permissible pressures of the wellbore and/or associated equipment. Where a screen-out condition is detected, the drone may autonomously be temporarily relocated, such as with the method disclosed in FIG. 31.

D. Example Computing Devices and Associated Media

The embodiments disclosed herein may include the use of a special purpose or general-purpose computer, as shown in the example computing device 1M of FIG. 32, including various computer hardware or software modules, as discussed in greater detail below. A computer may include a processor and computer storage media carrying instructions that, when executed by the processor and/or caused to be executed by the processor, perform any one or more of the methods disclosed herein, or any part(s) of any method disclosed.

As indicated above, embodiments within the scope of the present invention also include computer storage media, which are physical media for carrying or having computer-executable instructions or data structures stored thereon. Such computer storage media may be any available physical media that may be accessed by a general purpose or special purpose computer.

By way of example, and not limitation, such computer storage media may comprise hardware storage such as solid state disk/device (SSD), RAM, ROM, EEPROM, CD-ROM, flash memory, phase-change memory (“PCM”), or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other hardware storage devices which may be used to store program code in the form of computer-executable instructions or data structures, which may be accessed and executed by a general-purpose or special-purpose computer system to implement the disclosed functionality of the invention. Combinations of the above should also be included within the scope of computer storage media. Such media are also examples of non-transitory storage media, and non-transitory storage media also embraces cloud-based storage systems and structures, although the scope of the invention is not limited to these examples of non-transitory storage media.

Computer-executable instructions comprise, for example, instructions and data which, when executed, cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. As such, some embodiments of the invention may be downloadable to one or more systems or devices, for example, from a website, mesh topology, or other source. As well, the scope of the invention embraces any hardware system or device that comprises an instance of an application that comprises the disclosed executable instructions.

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts disclosed herein are disclosed as example forms of implementing the claims.

As used herein, the term ‘module’ or ‘component’ may refer to software objects or routines that execute on the computing system. The different components, modules, engines, and services described herein may be implemented as objects or processes that execute on the computing system, for example, as separate threads. While the system and methods described herein may be implemented in software, implementations in hardware or a combination of software and hardware are also possible and contemplated. In the present disclosure, a ‘computing entity’ may be any computing system as previously defined herein, or any module or combination of modules running on a computing system.

In at least some instances, a hardware processor is provided that is operable to carry out executable instructions for performing a method or process, such as the methods and processes disclosed herein. The hardware processor may or may not comprise an element of other hardware, such as the computing devices and systems disclosed herein.

In terms of computing environments, embodiments of the invention may be performed in client-server environments, whether network or local environments, or in any other suitable environment. Suitable operating environments for at least some embodiments of the invention include cloud computing environments where one or more of a client, server, or other machine may reside and operate in a cloud environment.

With reference briefly now to FIG. 32, any one or more of the entities disclosed, or implied, by FIGS. 1-31 and/or elsewhere herein, may take the form of, or include, or be implemented on, or hosted by, a physical computing device, one example of which is denoted at 1J. Part, or all, of the physical computing device 1J may comprise an element of a drone.

In the example of FIG. 32, the physical computing device 1J includes a memory which may include one, some, or all, of random access memory (RAM), non-volatile random access memory (NVRAM), read-only memory (ROM), and persistent memory, one or more hardware processors, non-transitory storage media, UI device/port, and data storage. One or more of the memory components of the physical computing device 1J may take the form of solid-state device (SSD) storage. As well, one or more applications may be provided that comprise instructions executable by one or more hardware processors to perform any of the operations, or portions thereof, disclosed herein. Such executable instructions may take various forms including, for example, instructions executable to perform any method, process, or portion of these, disclosed herein.

E. Further Aspects and Example Embodiments

Following are some further example aspects and embodiments of the invention. These are presented only by way of example and are not intended to limit the scope of the invention in any way.

Embodiments of a drone may include additional or alternative sensors to those disclosed elsewhere herein. Example sensors include, but are not limited to, any sensor configured to detect and report on any aspect of an operating environment of the drone. Thus, such sensors may be operable to detect various physical, electrical, and/or other parameters of an operating environment including, but not limited to, the presence of, and/or changes in, position of the drone, gases, fluids, sound, temperature, pressure, humidity, and particulate concentration. Other sensors and devices that may be employed in embodiments of a drone include, but are not limited to, lights, radio transmitters, radio receivers, GPS receivers, video cameras, still cameras, microphones, optical transmitters, optical receivers/detectors, hydrophones, rotary optical encoders, ultrasonic transmitters/receivers, and/or, magnetic and electromagnetic field detectors. Any sensor or device may be configured to transmit information concerning measurements made by that sensor or device. In some embodiments, the drone may be equipped to acoustically communicate, such as by sonar or similar techniques, with other tools, systems, and devices, downhole in the wellbore. These communications may be monitored and/or controlled from the surface, in some embodiments.

F. Aspects of Some Example Use Cases

One example use case concerns production logging. In general, production logging may be used to measure and interpret fluids, their properties, flow rates, and perforation efficiency to help operators increase wellbore and reservoir efficiencies. The well intervention drone may be deployed in the well by wireline or other methods of deployment in addition to self-deployment. Once the well intervention drone reaches its designated depth, it may self-propel itself up hole. While self-propelling, the well intervention drone may utilize its sensors as well as other techniques of interpretation to measure temperatures, pressures, fluid properties, fluid flow rates, as well as perforation efficiencies, and any and all data requested for retrieval. All the data gathered during the production log may be stored in a data acquisition system. This operation can be performed on producing wells, non-producing wells, and enhanced oil and gas recovery wells.

Another example use case concerns downhole wellbore data collection pre and post frac. This operation of downhole wellbore data collection may also take place during the frac'ing process while the drone is stationary. While stationary, data may be collected from each side of the sealing and isolation element providing a direct representation of wellbore activity pre, during and post frac. Data is also collected while propelling from stage to stage across the perforated and frac'd sections of the wellbore beginning at the furthest most depth of the wellbore. Data collection may include but not be limited to pressures, temperatures, flow rates, detection of harmful gasses, perforation orientation and depth.

Another example use case concerns pressure and casing integrity testing. Pressure and casing integrity testing may be performed in the wellbore to ensure the mechanical integrity of the casing. The well intervention drone may utilize its WIE (Module B) and hydraulic slips (Module C) to position itself in the designated area for testing. Fluids and/or fluid mixtures may be pumped against the drone to ensure that the casing/wellbore is not leaking. The drone may also self-propel throughout the designated area utilizing its sensors and other techniques of measurement to ensure that no corrosion, burst casing, or other mechanical issues with the casing/wellbore have taken place.

A further example use case concerns caliper measuring. Caliper measuring may be performed to measure the size and shape of the wellbore. The well intervention drone may be deployed in the well by wireline or other methods of deployment in addition to self-deployment. Once the well intervention drone reaches its designated depth, it may self-propel itself uphole. While self-propelling itself uphole, the well intervention drone may utilize its sensors to measure the shape and size of the wellbore as well as examine, log, and report on, any wellbore deformation. This data may be stored in a data acquisition system of the drone for later retrieval and analysis. In some embodiments, the drone may report this data in real time to another autonomous device, which may or may not be deployed in a wellbore, and/or to surface operators.

Another example use case concerns secondary sand and debris clean out. Secondary sand clean outs may be performed with coil tubing by injecting the coil tubing downhole with a bottom hole assembly consisting of a water nozzle or other milling apparatus connected to the downhole end of the coil. Fluid may be pumped through the coil tubing and out the downhole assembly to circulate and displace sand. The well intervention drone may be assembled with a milling head or other style of apparatus for displacing sand. This assembly may be deployed either by self-propulsion, wireline, or other methods of deployment to the designated area within the wellbore. Once the designated area is reached, fluid may be pumped against the well intervention drone causing the milling head to agitate in the wellbore. The fluid, as well as the well intervention drone power and driving mechanism, will self-propel the drone downhole while agitating the wellbore and displacing and milling sand. The well intervention drone may perform this operation throughout the wellbore until reaching the total depth of the well. Once the sand has been cleaned from the wellbore and the drone has finished its operation, the drone may self-propel back up the wellbore and be retrieved or exit the wellbore on its own.

Another illustrative example of a use case concerns water jet perforation. An additional module may be added to the well intervention drone to allow the drone to perforate the casing. An embodiment of an example module is shown in FIGS. 33 and 34. This module may comprise, for example, a water and sand mixture inlet (1K), a series of pumps (2K), a series of inlet valves (3K), a series of pressurized water/sand perforation nozzles (4K), a series of pressure/flow rate sensors (5K), and a series of nozzle valves (6K). With particular reference to FIG. 33, the water/sand mixture may be pumped from the surface and enter the body of the water jet perforation section through the inlet 1K. This high pressure mixture of fluid may then used to create perforations in the casing with assemblies that may involve some or all of the components labeled 2K, 3K, 4K, 5K, and 6K.

Particularly, the pump 2K, may be used to increase the pressure of the already pressurized fluid mixture. This pressurized fluid mixture may then be directed through the perforation nozzle 4K, which has a reducing inner diameter which further increases pressure and directs fluid flow. As the high pressure fluid flows through 4K, it will then cut/perforate the wellbore casing, the concrete, and the formation around the wellbore. The pressure/flow rate sensor 5K may be configured with a time relay. Once the flow rate and pressure begin to drop, the pressure/flow rate sensor 5K may indicate, by a pressure drop/differential, a positive perforation. The time relay may be set to a specific time to send a switch signal to the valve 3K to open, and for valve 6K to close. Once the uphole assembly has successfully perforated the casing, the next downhole assembly may be activated to begin perforating the wellbore. This perforation module may be arranged in various configurations with various lengths and numbers of perforating sections, not confined to the six assemblies shown in FIG. 33.

Fishing—this method can either be operated through self propulsion or by being tethered to equipment on the surface. By use of cameras or other optical devices, the drone can identify the object to be fished or retrieved from the well. The drone can also be equipped with a fishing or retrieval tool to latch on to the object to be fished. The drone can also be equipped with such devices that will prepare the object for fishing.

Conveying—including but not limited to wireline, fiber optic or other tools and devices throughout but not limited to the lateral sections of the wellbore.

Embodiment 1. An apparatus, comprising: a body; a propulsion system configured to move the body in a forward direction and in a reverse direction; and a reusable sealing and isolation element connected to the body and configured to be deployed so as to selectively seal and isolate sections or stages in a wellbore when the apparatus is disposed in the wellbore.

Embodiment 2. The apparatus as recited in embodiment 1, wherein the apparatus comprises an autonomous drone.

Embodiment 3. The apparatus as recited in any of embodiments 1-2, wherein the propulsion system comprises: a power source; one or more extendible/retractable propulsion systems, wherein one of the propulsion systems comprises a motor and one or more wheels disposed on an outer portion of the body; and a gear box that connects the motor to the wheels.

Embodiment 4. The apparatus as recited in embodiment 3, wherein the power source comprises one or more rechargeable batteries configured to be wirelessly charged down hole.

Embodiment 5. The apparatus as recited in embodiment 3, wherein the power source comprises rechargeable batteries.

Embodiment 6. The apparatus as recited in any of embodiments 1-5, wherein the apparatus is self-propelled.

Embodiment 7. The apparatus as recited in any of embodiments 1-6, wherein the body is articulated.

Embodiment 8. The apparatus as recited in any of embodiments 1-7, further comprising one or more hardware processors and non-transitory storage media carrying instructions that are executable by the one or more hardware processors to cause the seal to expand and retract according to a specified schedule.

Embodiment 9. The apparatus as recited in any of embodiments 1-8, wherein the reusable sealing and isolation element comprises a seal configured to assume an expanded state and a retracted state, and when the seal is in the expanded state in the wellbore, the seal isolates sections within the wellbore such that fluid in the wellbore cannot pass by the apparatus.

Embodiment 10. The apparatus as recited in any of embodiments 1-9, wherein no portion of the reusable sealing and isolation element remains permanently in the wellbore.

Embodiment 11. The apparatus as recited in any of embodiments 1-10, wherein the apparatus is operable to autonomously deploy the reusable sealing and isolation element.

Embodiment 12. A method, comprising: temporarily sealing and isolating a portion of a wellbore with a reusable sealing and isolation element; and unsealing or de-isolating the portion of the wellbore by temporarily changing a configuration of the reusable sealing and isolation element.

Embodiment 13. The method as recited in embodiment 12, wherein the method is performed autonomously by a drone.

Embodiment 14. The method as recited in any of embodiments 12-13, further comprising moving the entire reusable sealing and isolation element to another location in the wellbore, and isolating the wellbore at another location with the reusable sealing and isolation element.

Embodiment 15. The method as recited in any of embodiments 12-14, wherein temporarily sealing and isolating a portion of the wellbore with the reusable sealing and isolation element, comprises temporarily changing the configuration of the reusable sealing and isolation element relative to a configuration of the reusable sealing and isolation element when the wellbore is sealed and isolated with the reusable sealing and isolation element.

Embodiment 16. The method as recited in any of embodiments 12-15, wherein after the wellbore is de-isolated, no post-remediation of the reusable sealing and isolation element is required at the site where the reusable sealing and isolation element had been positioned.

Embodiment 17. The method as recited in any of embodiments 12-16, wherein the well intervention drone comprises a perforating module operable to perforate the wellbore.

Embodiment 18. The method as recited in any of embodiments 12-17, wherein the well intervention drone autonomously mitigates sand and debris screen outs.

Embodiment 19. The method as recited in any of embodiments 12-18, further comprising wirelessly charging a battery of the drone while the drone is in a wellbore.

Embodiment 20. A method, comprising: deploying a drone to a downhole location; and using the drone to collect data uphole and/or downhole of a sealing and isolation element while the sealing and isolation element is engaged with the drone and/or disengaged from the drone.

Embodiment 21. The method as recited in embodiment 20, where data collection is performed pre-frac, during frac, and/or post-frac.

Embodiment 22. The method as recited in any of embodiments 20-21, where the data collected comprises data about a wellbore environment, wellbore conditions, and/or, wellbore activity.

Embodiment 23. The method as recited in any of embodiments 20-22, wherein the data is collected autonomously by the drone.

Embodiment 24. The method as recited in any of embodiments 20-23, wherein the data is collected while the drone is unconnected to the surface or equipment on the surface.

Embodiment 25. The method as recited in any of embodiments 20-24, wherein data collection is performed autonomously by the drone, and the data collection begins when the drone is at its deepest location in a well, and data collection continues at least part of a time during which the drone propels away from the deepest location.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 

What is claimed is:
 1. An apparatus, comprising: a body; a propulsion system configured to move the body in a forward direction and in a reverse direction; and a reusable sealing and isolation element connected to the body and configured to be deployed so as to selectively seal and isolate sections or stages in a wellbore when the apparatus is disposed in the wellbore.
 2. The apparatus as recited in claim 1, wherein the apparatus comprises an autonomous drone.
 3. The apparatus as recited in claim 1, wherein the propulsion system comprises: a power source; one or more extendible/retractable propulsion systems, wherein one of the propulsion systems comprises a motor and one or more wheels disposed on an outer portion of the body; and a gear box that connects the motor to the wheels.
 4. The apparatus as recited in claim 3, wherein the power source comprises one or more rechargeable batteries configured to be wirelessly charged downhole.
 5. The apparatus as recited in claim 3, wherein the power source comprises rechargeable batteries.
 6. The apparatus as recited in claim 1, wherein the apparatus is self-propelled.
 7. The apparatus as recited in claim 1, wherein the body is articulated.
 8. The apparatus as recited in claim 1, further comprising one or more hardware processors and non-transitory storage media carrying instructions that are executable by the one or more hardware processors to cause the seal to expand and retract according to a specified schedule.
 9. The apparatus as recited in claim 1, wherein the reusable sealing and isolation element comprises a seal configured to assume an expanded state and a retracted state, and when the seal is in the expanded state in the wellbore, the seal isolates sections within the wellbore such that fluid in the wellbore cannot pass by the apparatus.
 10. The apparatus as recited in claim 1, wherein no portion of the reusable sealing and isolation element remains permanently in the wellbore.
 11. The apparatus as recited in claim 1, wherein the apparatus is operable to autonomously deploy the reusable sealing and isolation element.
 12. A method, comprising: temporarily sealing and isolating a portion of a wellbore with a reusable sealing and isolation element; and unsealing or de-isolating the portion of the wellbore by temporarily changing a configuration of the reusable sealing and isolation element.
 13. The method as recited in claim 12, wherein the method is performed autonomously by a drone.
 14. The method as recited in claim 12, further comprising moving the entire reusable sealing and isolation element to another location in the wellbore, and isolating the wellbore at another location with the reusable sealing and isolation element.
 15. The method as recited in claim 12, wherein temporarily sealing and isolating a portion of the wellbore with the reusable sealing and isolation element, comprises temporarily changing the configuration of the reusable sealing and isolation element relative to a configuration of the reusable sealing and isolation element when the wellbore is sealed and isolated with the reusable sealing and isolation element.
 16. The method as recited in claim 12, wherein after the wellbore is de-isolated, no post-remediation of the reusable sealing and isolation element is required at the site where the reusable sealing and isolation element had been positioned.
 17. The method as recited in claim 12, wherein the well intervention drone comprises a perforating module operable to perforate the wellbore.
 18. The method as recited in claim 12, wherein the well intervention drone autonomously mitigates sand and debris screen outs.
 19. The method as recited in claim 13, further comprising wirelessly charging a battery of the drone while the drone is in a wellbore.
 20. A method, comprising: deploying a drone to a downhole location; and using the drone to collect data uphole and/or downhole of a sealing and isolation element while the sealing and isolation element is engaged with the drone and/or disengaged from the drone.
 21. The method as recited in claim 20, where data collection is performed pre-frac, during frac, and/or post-frac.
 22. The method as recited in claim 20, where the data collected comprises data about a wellbore environment, wellbore conditions, and/or, wellbore activity.
 23. The method as recited in claim 20, wherein the data is collected autonomously by the drone.
 24. The method as recited in claim 20, wherein the data is collected while the drone is unconnected to the surface or equipment on the surface.
 25. The method as recited in claim 20, wherein data collection is performed autonomously by the drone, and the data collection begins when the drone is at its deepest location in a well, and data collection continues at least part of a time during which the drone propels away from the deepest location. 